Hydrocarbon compositions derived from pyrolysis of post-consumer and/or post-industrial plastics and methods of making and use thereof

Abstract

Disclosed herein are hydrocarbon based compositions derived from pyrolysis of a feedstock comprising post-consumer and/or post-industrial plastics and methods of making and use thereof.

What is claimed is: 
     
       1. A wax derived from pyrolysis of a feedstock comprising post-consumer and/or post-industrial plastics, wherein:
 the wax is produced at an industrial scale; 
 the wax comprises a mixture of different hydrocarbons, any of which can optionally be substituted, wherein 60% or more of the mixture (w/w) comprises C 20 -C 45  hydrocarbons; and 
 the wax has:
 a sodium content of from 0.001 to 150 ppm; 
 an iron content of from 0.001 to 2.5 ppm; 
 a calcium content of 0.001 to 50 ppm; and 
 a phosphorus content of from 0.001 to 50 ppm. 
 
 
     
     
       2. The wax of  claim 1 , wherein from 60 to 80% of the mixture (w/w) comprises C 20 -C 45  hydrocarbons. 
     
     
       3. The wax of  claim 1 , wherein the mixture comprises:
 20-30% C 9 -C 20  hydrocarbons, 
 20-30% C 20 -C 24  hydrocarbons, 
 20-30% C 24 -C 28  hydrocarbons, and 
 10-20% C 28 -C 32  hydrocarbons. 
 
     
     
       4. The wax of  claim 1 , wherein the mixture is substantially free of C 1 -C 8  hydrocarbons. 
     
     
       5. The wax of  claim 1 , wherein the mixture comprises:
 80-100 wt. % saturated hydrocarbons; 
 0-5 wt. % unsaturated non-aromatic hydrocarbons; and 
 0-15 wt. % aromatics. 
 
     
     
       6. The wax of  claim 1 , wherein the wax has a melting point of from 40° C. to 55° C., a congealing point of 40° C. to 55° C., or a combination thereof. 
     
     
       7. The wax of  claim 1 , wherein the wax has a final boiling point of 950° F. to 1300° F. 
     
     
       8. The wax of  claim 1 , wherein the wax has a total chloride content of 50 ppm or less. 
     
     
       9. The wax of  claim 1 , wherein the wax has a nitrogen content of 300 ppm or less. 
     
     
       10. The wax of  claim 1 , wherein the wax has a silicon content of 125 ppm or less. 
     
     
       11. The wax of  claim 1 , wherein the wax has a sodium content of from 0.001 to 100 ppm. 
     
     
       12. The wax of  claim 1 , wherein the wax has an iron content of from 0.001 to 100 ppm. 
     
     
       13. The wax of  claim 1 , wherein the wax has a phosphorus content of from 0.001 to 45 ppm. 
     
     
       14. The wax of  claim 1 , wherein the wax has a sulfur content of 500 ppm or less. 
     
     
       15. The wax of  claim 1 , wherein the wax has a copper content of 10 ppm or less, a nickel content of 100 ppm or less, a vanadium content of 25 ppm or less, or a combination thereof. 
     
     
       16. The wax of  claim 1 , wherein the wax has:
 a total chloride content of 25 ppm or less; 
 a nitrogen content of 275 ppm or less; 
 a silicon content of 100 ppm or less; 
 a sodium content of from 0.001 to 10 ppm; 
 an iron content of from 0.001 to 2 ppm; 
 a phosphorus content of from 0.001 to 45 ppm; 
 a sulfur content of 10 ppm or less; 
 a calcium content of 5 ppm or less; 
 or a combination thereof. 
 
     
     
       17. The wax of  claim 1 , wherein the wax has a Reid Vapor Pressure of 12.5 psig or less. 
     
     
       18. The wax of  claim 1 , wherein the wax has a total sediment content of 0.5 vol. % or less, an n-heptane insoluble content of 0.5 wt. % or less, a total acid number of 1 mg KOH/g or less, or a combination thereof. 
     
     
       19. The wax of  claim 1 , wherein the wax has:
 a Reid Vapor Pressure of 12.5 psig or less; 
 a final boiling point of 950° F. to 1300° F.; 
 a pour point of 30° F. to 60° F.; 
 a total chloride content of 50 ppm or less; 
 a nitrogen content of 300 ppm or less; 
 a silicon content of 125 ppm or less; 
 a sulfur content of 500 ppm or less; 
 a calcium content of 50 ppm or less; 
 or a combination thereof. 
 
     
     
       20. A method of making the wax of  claim 1 , wherein the method comprises pyrolysis of a feedstock comprising post-consumer and/or post-industrial plastics. 
     
     
       21. The method of  claim 20 , wherein the method produces the wax in a volume of from 10,000 to 1,000,000 gallons per 5 to 90 days. 
     
     
       22. A composition, wherein the composition is derived from the wax of  claim 1 . 
     
     
       23. The composition of  claim 22 , wherein the composition comprises a lubricating oil, a mineral oil, a paraffin wax, a binder, a processing aid, kerosene, white oils, liquefied petroleum gas (LPG), naphtha, diesel and gas oil, gasoline, diesel fuel, asphalt, automotive fuel, aviation fuels, base oil, bitumen, cadalene, cutting fluid, fuel oil, heating oil, hydrocarbon solvents, microcrystalline wax, mineral oil, motor fuel, motor oil, naphthenic acid, petroleum ether, petroleum jelly, petroleum resin, retene, or a combination thereof. 
     
     
       24. A method of making the composition of  claim 22 , wherein the method comprises processing of the wax, wherein the processing comprises refining, filtering, cracking, hydrotreating, or a combination thereof. 
     
     
       25. A method of use of the composition of  claim 22 , wherein the method comprises: feeding the composition into a petroleum refinery, a catalytic cracking system, a thermal cracking system, a polymerization system, or a combination thereof; and using the composition as a hydrocarbon feedstock for said petroleum refinery, catalytic cracking system, thermal cracking system, polymerization system, or a combination thereof. 
     
     
       26. An article of manufacture, wherein the article of manufacture comprises or is derived from the wax of  claim 1 . 
     
     
       27. The article of  claim 26 , wherein the article comprises packaging, film, fibers, carpets, clothing, molded articles, extruded pipes, a medical device, lubricant, candles, adhesives, packaging, rubber, cosmetics, fire logs, bituminous mixtures, superficial wear coatings, asphalt, sealing coatings, automotive fuel, aviation fuels, base oil, bitumen, cadalene, cutting fluid, diesel fuel, fuel oil, gasoline, heating oil, hydrocarbon solvents, kerosene, microcrystalline wax, mineral oil, motor fuel, motor oil, naphtha, naphthenic acid, paraffin wax, petroleum ether, petroleum jelly, petroleum resin, retene, tar, fertilizer, flooring, perfume, insecticide, soap, vitamin, amino acid, wood-based composites, oriented-strand board (OSB), particleboard, hardboard, medium density fiberboard, gypsum board, crayons, paper and carton coatings, or a combination thereof. 
     
     
       28. A composition, wherein the composition comprises the wax of  claim 1 . 
     
     
       29. A method of use of the composition of  claim 28 , wherein the method comprises: feeding the composition into a petroleum refinery, a catalytic cracking system, a thermal cracking system, a polymerization system, or a combination thereof; and using the composition as a hydrocarbon feedstock for said petroleum refinery, catalytic cracking system, thermal cracking system, polymerization system, or a combination thereof.